Beer Processing Solutions 5600 01-08-2008 US

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Beer Processing Solutions



Table ocontents

Introduction 3Brewing Process Diagram 4Complete Product Range 5Complete Process Solutions 6-7Automation Services 8-9Maintenance Service 10Wort cooling, yeast dosing,wort aeration 11-12Water deaeration 13-14In-line blending and mixing 15-16Carbonation and nitrogenation 17-18High gravity brewing 19-20Pasteurizing 21-22CIP 23

Fermentation & maturation 24F i l t r a t i o n 2 4

2



APV pioneered many o the key

technologies involved in the brewery

industry As early as 1910, APV

made the rst welded aluminium

beer tank on the basis o a British

patent, and through its commitmentto innovation, the company has

continued to make important

contributions to the industry ever

since APV has established many

milestones in brewing technology,

with results that are still valid

throughout the world today

In 1914 APV developed a system or

the culture o pure yeast and in 1923

the company revolutionized wort

cooling by introducing the world’s rst

brewery plate heat exchanger

Since then, many more developments

have been introduced, placing APV

in a better position than ever to serve

the brewery industry in all specialty

processes

Today APV oers process automation

systems, individual brewery

process units, and a wide range

o components including pumps,

valves and heat exchangers All

APV equipment and systems can besupported by a variety o ater sales

services

Our rst steps into the brewery equipment

business began as early as 1910

Beer Types with Approximate Alcohol by Volume

Bottom Fermented Top Fermented

Malt Malt Wheat Malt

Münchner 48% Trappist 9-108% Strong Ale 61-84% Weizenbier 48-56%

Pilsner/Pilsener 42-5% Kölsch 48% Bitter stout 44-75% Berliner Weisse 33%

Ur-types 49% Brown Ale 25-45% Milk stout 37-38% Gueuze-Lambic 5%

Danish Lager 42-47% Pale Ale 43-66% Russian stout 95%

Bock 7-73% Mild Ale 25-36% Light Ale 29-4%

Doppelbock 7-73% Bitter Ale 30-40% Steam Beer 48%



The Brewing Process

4



APV provides a selection o

standardized process units, which

could be described as a series o

building blocks These ulll various

brewing processes and include:

• WortMaster – Wort cooling, yeast

dosing and wort aeration

• Derox – Cold and hot water

deaeration

• BlendMaster – In-line blending and

mixing

• CarboMaster – Carbonation and

nitrogenation

• HGBMaster – High gravity brewing

• PU Pasteurizer – Controlled beerpasteurization

• CIP Master

Focused on adding value to your

product

Our process units are designed

to exceed industry standards and

enhance the value o your products

To highlight how value is added to

your products and processes, we

have developed the ollowing symbols

or your reerence

Product

uniormity

homogenous products

Flexible

production

ast product changeover

Economical

production

cost saving processes

Proven

security

tested equipment

From individual units to totally

automated solutions

Every unit can be supplied as

a stand-alone system, ideally

equipped or smooth and trouble ree

operation and suitable or integration

into your central control system But

you will gain additional benets with

a combination o units, which have

been specically designed to operate

together or high perormance, both

rom a mechanical and a control

perspective

APV can guarantee you a process

solution tailored to your needs

A Complete Product Range

The unit values are signifcant

APV Provides: Capabilities: Customer Values:

An intelligent processing unit Conguration as requiredReal time plant data:

• Predictive maintenance• On-line documentation• Final product monitoring• Traceable production

Improved process:• Protability• Consistency• Security

Lower operating costLonger running time

A Plug & Produce™ unit Very short commissioning timeLow installation costNo intererence to existing production schedulesReduced time rom order to productionSeamless integration to all plantsEasy to extend

Faster return on investmentEasy expansion o existing plant

Proven standards Improved unctionalityHygenic design

Good reliability

Improved repeatabilityProduct integrity saeguarded

State o the art processes Easy operationLow energy consumptionReduced wasteLow noise emission levels

Quick and easy operator trainingEnvironmental improvementsImproved company image

A compact unit design Container ttedLow shipment costSmallerproduction area requiredMoveable equipmentFast delivery time

Shorter delivery timeHigher capacity/m²

Maintenance service Easy maintenanceOptimal APV serviceFixed maintenance costsA reduction in unscheduled downtimeLimited spare parts requirement

Cost eective maintenanceHigher productivity



APV draws on decades o

experience in project engineering and

management or the brewery industry

Its extensive range o reerenceinstallations includes everything rom

a single process line to complete

greeneld turnkey beer processing

solutions

To meet today’s demand or modern,

highly ecient production acilities,

APV’s in-depth knowledge o brewing

top quality beers is complemented by

expertise in process automation and

management inormation systems

APV’s technological excellence

covers processes such as

ermentation and storage, yeast

handling and treatment, beer

processing, bright beer and

pasteurization Furthermore, we have

vast experience in the areas o wort

cooling, water deaeration, and high

gravity brewing Our CIP systems

complete the process Whereverappropriate, APV integrates its strong

range o standard process units into

a project

We believe our experience is our

most important asset Previous

highly successul installations are

our customer’s best guarantee that a

brewery project will be implemented

on time and within budget

Our experience ranges rom

traditional methods to highly

automated systems based around the

latest proven technologies

Highly automated systems deliver

improved eeciencies, resulting in a

aster return on investment, due to:

• More production time

• Less cleaning time

• Minimum use of water, chemicals and

energy

• Fewer operators

They also improve batch control,

resulting in product traceability and

fexibility

Further benets or the brewmaster

and management are:

• A “paper free” process control

system which can interace with ERP

systems

• Material and quality tracking

capability

• Full compatibility with brew-house

and lling plant as well as with other

production plants in the brewing

group

Process Engineering

APV uses its extensive experience

in the development, planning and

implementation o brewing steps

in close co-operation with our

customers’ brewmaster, technologists

and process engineers Careul

Complete Process SolutionsAdding value or the brewmaster

teamwork ensures that we

understand and recognize each o our

customers’ specic needs

Detailed Engineering

This starts with the PID and

process description, ollowed by the

development o installation pipeline

circuit and connection plants, cable

lists, unctional descriptions, program

sequences, energy calculations,

component specications, interace

denitions, spare parts lists and

operating instructions and manuals

– all dedicated exactly to ourcustomers’ specic brewing needs

Hygienic Design

Our design is based on the latest

international standards or hygienic

design APV uses standard design

elements, which are constantly

reviewed to meet the highest

standards

Health and Saety

HACCP/HAZOP studies can be

undertaken, reviewing equipmentspecications relative to process fow

diagrams to determine whether there

are any quality, health and saety

issues, which need to be addressed

6



Each process step is analyzed to

establish whether the equipment and

control systems are adequate or sae

operation under normal, abnormal andCIP conditions

Latest Design Tools

APV uses the latest design tools

The use o 3D models, with possible

access to ull-scale modeling rom

AutoCAD, provides improved

saety eatures by maintaining data

throughout the project via single

entry to the database Furthermore,

the existing AutoCAD platorm orcommunication with most customers’

CAD Systems is maintained

Project Management –

a single point o contact

APV project managers are our

customers’ single point o contact

They are highly experienced

and acutely aware o all critical

implementation aspects Excellent

coordination skills enable them totranslate the eorts o APV suppliers

and other sub-suppliers into

successul projects

Environmentally Saer Processes

In response to an increasing need

or environmentally acceptable utility

services, energy optimization throughsound design principles is always

observed Waste minimization and

health and saety issues are always

careully considered

Installation Supervision

APV supervisors are internationally

experienced and accustomed to all

kinds o local working environments

Armed with excellent co-operation

skills, they are specialists inaccessing appropriate local

manpower

Optimizing

Working Procedures

Consistent working procedures in

sales, engineering and management

are an important part o the value

APV adds to a project We have

thereore been certied to ISO

9001 Standards But that hasnever been our nal goal Through

quality improvement programs,

working procedures are constantly

monitored and challenged to increase

productivity and eciency in all parts

o our business

Training o People

Breweries are operated by ewer and

ewer highly trained sta, which oten

results in the need or an exceptional

degree o automation and integration

APV provides tailored training

courses or our customers’ personnel

in both process and automationtechnology Designed to extend their

skill base, increase their specialist

knowledge and update them on

the latest trends, these courses

are oered either at our customers’

brewery or on APV premises



Automation and Perormance Services SolutionsAPV FactoryExpert

Driving manuacturing excellence

FactoryExpert is APV Automation &Perormance Services It combines

innovative solutions with reusable

engineering applications on open

platorms to meet our customer

automation specications

We offer state-of–the-art automation

solutions and services designed

to international standards based

on in-depth process knowledge

together with manuacturing know-how and engineering expertise

that meet regulatory requirements

FactoryExpert enables customers

to extend their perormance gains

across their business

APV FactoryExpert Value

Streams

APV FactoryExpert comprises ve

strategic value streams to meet

our customers’ automation andmanuacturing execution needs

• Automation Service for

customers’ existing automation

equipment oering maintenance and

support programs, spare parts, etc…

maintaining and improving conditions

to maximize plant uptime

APV FactoryExpert is vendor

independent, it can include, or

example control systems and human

machine interaces (HMIs) rom

Siemens, Rockwell, Mitsubishi,

Wonderware, etc This enables true

versatility in our solutions

8



ERP Integration

MES Applications

Automation Systems

Automation Migration

Automation Service

• Automation Migration for ourcustomers with an installedbase o ageing and obsoleteautomation equipment whichcan no longer adequately sup-port their business Furthermore,Automation Upgrade or systemsthat require additional unctionalityto meet automation and controlrequirements

• Automation Systems consisting

o PLC and HMI as part o ourproject oering These can be inthe orm o a single skid unit toplant wide automation solutions

• MES Applications targeting manu-acturing and equipment perorm-ance, production execution, qualityand tracking We oer a suite oengineered applications designedto deliver the right inormation, atthe right time, to the right people,in the right context to drive utureactions in our customers’ or-ganizations to drive manuacturingexcellence

• ERP Integration solutions thatlink and integrate the plant foorautomation systems to ourcustomer’s enterprise or businesslayer



Until recently, the impact o

maintenance operations on round-

the-clock production, quality,

manuacturing fexibility, traceability,

plant saety and environmental

protection has been largely ignored

APV recognizes that cost-eective

perormance o your APV equipment

is directly dependent on the ability to

design and implement a cost-eective

maintenance program

In response to these requirements,

and as part o the on-going expansion

o our customer support strategy,

APV Maintenance Services adapt to

your specic requirements

Maintenance Services consists o

multiple levels o service agreements

in order to create the ideal balance

o fexibility, improved productivity,

increased up-time and better nancial

perormance o all APV equipment

Dierent service agreements can

be created or our customers For

example:

• BasicCare - APV service when you can plan

ahead- Balance o uptime and

economics or non-critical assets

• ClassicCare - Comprehensive APV service

support- When service delays are not an

option

• AdvantageCare - APV service coverage or yourmost critical equipment

- Proactive approach toequipment perormance

• TotalCare - APV service management and

support or the entire plant- Plant-wide strategy to improve

mission eectiveness

Each agreement includes certain

critical items, with each level providing

progressively increasing support

capability (see table below)

APV is committed to providingproactive service solutions These

Maintenance Services agreements

provide the best possible service to

maximize your perormance and deliver

improved return on your investment

Maintenance Services

Total Care Advantage Care Classic Care Basic Care

Critical parts delivered same Critical parts delivered within Critical parts on site within Parts on site witin 72 hours

or next day service 24 hours 48 hours

Emergency service technician Emergency service technician Emergency service technician Emergency service response

on site within same or next on site within same or next on site within same or next @ 10% discount

day day day

APV Preventive Maintenance APV Preventive Maintenance APV Preventive Maintenance One annual planned

program, 24/7/365 program, 24/7/365 program, Monday to Friday maintenance visit

8am-5pm

Free emergency service, Emergency service, Emergency service, Spare parts @ 10% discount

24/7/365 24/7/365 Monday-Friday, 8am-5pm

Wear parts and service parts Wear parts and service parts Wear parts included Recommended wear parts

included included replacement scheme

Other spare parts @ 15% Other spare parts @ 15% Other spare parts @ 15% Technical telephone support,

discount discount discount Monday-Friday, 8am-5pm

Technical telephone support, Technical telephone support, Technical telephone support,

24/7/365 24/7/365 Monday-Friday, 8am-5pm

Modem support included Modem support included Modem support - optional

Strategy or service Strategy or service Strategy or service

partnership seminar partnership seminar partnership seminar

Sotware upgrades Predictive maintenance on

critical items

Plant availability guarantee Sotware upgrades

Designated APV maintenance Rebuilding & retroitt ing

manager consultancy

Continuous process cost

reduction

Guaranteed perormance

guarantees on critical items

Annual process knowledge

analysis

Rebuilding & retroitting

consultancy

Operator audit and training

@20% discount

APV service management APV service coverage for Comprehensive APV APV service when you can

and support for the your most critical equipment service support plan ahead

entire plant

Plantwide strategy to Proactive approach to When service delays aren´t Balance of uptime and

improve mission equipment performance an option economics for

effectiveness non-critical assets

A Systematic Program o Strategic Maintenance

10



The WortMaster product rangecovers units designed or the

processes between the brewhouse

and ermentation, including wort

cooling, yeast dosing and wort

aeration

In addition to ast and ecient wort

cooling, WortMaster units deliver

eective and accurate in-line dosing

o yeast and air/oxygen by means o

the patented APV gas injector

Oered in a wide range o capacitiesfrom 50 – 1200 hl/hr, all WortMaster

units are designed and developed or

easy integration with existing lines

WortMaster

- adds value

The WortMaster adds value to your

products and processes in the

ollowing ways:

Product uniormity:

• Constant monitoring and improved

regulation o the process

• Repeatable fermentation

perormance

Economical production:• Higher accuracy in yeast and oxygen

dosing

• Reduced fermentation time

Flexible production:

• Turn down ratio to 25% of nominal

capacity

• Constant yeast/oxygen ratio,

regardless o fow

Proven security:• Fully CIP-cleanable

• Traceable production data

WortMaster – Wort Cooling, YeastDosing & Wort Aeration

Ensure economical production by minimizing the use o time and additives



FunctionalDescription

Wort Cooling - Hot wort rom the

brewhouse must be cooled prior to

the addition o yeast or ermentation

This is achieved using a state o the

art plate heat exchanger with a wide

channel, which reduces the cleaningrequirement while maintaining good

heat transer eciency Additional

attractive eatures include a high

perormance clamping system,

improved hanging area and EasyClip

gaskets, all o which contribute to

reduced maintenance and spare parts

requirements

The wort cooler can be designed as a

single section cooler using ice wateror as a double section cooler or

brewing water and rerigerant

Wort Aeration - Brewing yeast

requires oxygen to multiply

Traditionally this has been supplied

by blowing air through the wort with

various types o nozzles and mixers

The result was oten varying oxygen

levels o typically 10-12 mg O2/l

depending on pressure, temperatureand the original gravity o the wort

Specied O2 levels with high gravity

worts are usually higher and thus pure

oxygen is oten used to achieve levels

above 18 mg O2/l

The APV Gas Injector allows these

levels to be achieved by a ast

consistent mixing o wort and either

air or oxygen

Yeast Dosing - Yeast can be added

to complete the wort treatment This

has the advantage o adding yeast

immediately to the cooled wort

The actual method used can refect

local practice and the automation

allows accurate MIS/MES integration

In the event o lack o product fow,

the yeast supply is shut o

Options

Cooling• DuoSafety Plates - Additional

product protection

• ParaWeld Plates - Allow the use of

NH3 as rerigerant

• Bypass – Options are available for

bypassing the plate heat exchanger

to enable such operations as hot

and/or cold wort diversion and back

washing

Aeration

• Manual Adjustable Head – Any

adjustment or fow and specication

must be made manually

• Modulating Head – Automatic

adjustment o the head can be made

rom the control system This option

can be retrotted to the manual head

Dosing

• Flow Measurement – The yeast can

be dosed by means o a magnetic

fowmeter

• Tank Contents Measurement – The

amount o yeast can be dosed on the

basis o tank contents measured by a

load cell

• Yeast Cell Measurement – The

amount o yeast can be dosed on

the basis o instrumentation that

measures the yeast cell

concentration

Common

• Original Extract Measurement -

Completed through the means o

a sound velocity sensor or density

measurement

• Oxygen Measurement – The oxygen

content o the wort can be measured

using an appropriate instrument

• Blending Separation - The simple

blending “T” can be replaced with

a 4 port double seat valve and stopvalve to separate the product and

component loops or cleaning

• High Accuracy Blending – A

variation o this technology using

mass fow measurement is capable o

even higher accuracy and is used or

blending o components such as hop

extract or color

• Conductivity Measurement –

Product separation can be measured

by means o conductivity to minimize

product loss

BREW WATER

WORT

STERILE AIR

AERATED WORT

K K

GLYCOL

GLYCOL

BREW WATER

12



Deaerated water is used in the

brewing industry to minimize damage

to beer through oxidation It is used

as a medium or purging mains andequipment and post ermentation as

part o the brewing process

The Derox product range covers units

designed or deaeration o processing

water Derox is used where a low O2

content is required or recommended,

or example or the lauter tun,

blending o bright beer and in High

Gravity Brewing (HGB) processing

Deaeration can be perormed by two

dierent systems - cold (Derox) or hot

(Derox+) deaeration The hot system

heats the water to high temperature,

which reduces the risk o inection

and helps remove contaminants The

cold system is capable o achieving

low levels o oxygen with low capital

and production costs

All Derox Units are designed anddeveloped especially or easy

integration to existing lines, with a

wide and fexible capacity range

Derox (cold)

- adds value

The standard capacity range is 30 –

1500 hl/h

The Derox adds value to your


ollowing ways:

Product uniormity:

• Constantly low oxygen content 50

ppb at 12°C* (below 30 ppb at>20°C*)

• Continuous monitoring for required

specication

Economical production:

• Low running costs

• Space-saving design (high capacity/

m2)


• Variable capacity and high turn down

• Independent of water inlet

temperature (option)

• Variable deaeration levels

Proven security:

• No rings and plates inside vacuum

tanks

• Fully CIP-cleanable

Derox+ (hot)- adds value

The standard capacity range is 50 –

400 hl/h

The Derox+ adds value to your


ollowing ways:

Product uniormity:

• Constantly very low oxygen content

(below 20 ppb*)

• Continuous monitoring for requiredspecication

• Continuous removal of undesirable

THF gases




m2)


• High turn down ratio (down to 25%o nominal capacity)

• Independent of water inlet tempera-

ture

Proven security:


tanks

• Deaerated water is pasteurized


Derox – Cold and Hot Water DeaerationImprove your beer quality with the Derox Deaerator

* Measured as a standard deviatio




Hot deaeration

Water entering the unit is warmed by

means o the regenerative section o

a plate heat exchanger

Ater the regenerative section, the

water enters a heating section where

the temperature is raised to about

88ºC The water is then sprayed

into the deaeration tank via special

nozzles

The deaeration tank is kept under

vacuum so that the oxygen is removed

with a minimum o water vapor

The deaerated water is cooled in

the regenerative section o the plate

heat exchanger and the nal outlet

temperature is achieved using a

chilling section or a separate cooler,

depending upon the rerigeration

available

The deaeration tank does not contain

packing and is easily cleaned

Cold deaeration

Water is sprayed into the bottom

vacuum tank, which starts the oxygen

removal process

The water is then pumped and

sprayed into the top vacuum tank via

an injector where stripping gas (either

CO2 or N2) may be applied

From the top tank the water alls

through a pipe with a vent which

allows some o the water to return

into the bottom tank The level in this

bottom tank is controlled by means

o a level switch, which controls the

water inlet valve

The remaining water is discharged

rom the unit via an adjustable

manual-regulating valve

The unit is designed or CIP and does

not contain packing

Options

Hot deaeration

• CO2 Stripping - The use o a small

amount o stripping gas can allow

the energy lost through fashing to be

reduced

Cold deaeration

• Chilling - Chilling of water to

match beer temperature Dierent

congurations are available

• UV Water Disinfection - Disinfec-tion o the incoming water can be

obtained by the use o an ultra-violet

disinection unit

• Seal Water Cooling - In cases where

the seal water will exceed 25°C it is

advisable to t an optional seal water

cooler

DEAERATED WATER

WATER/CIP

CO2 / N2

Derox (Cold)

• Preheater - Values below 003 ppm

residual O2 can be achieved with a

water temperature o about 20°C

In cases where this water inlet

temperature is not a normal value, a

pre-heater consisting o a shell and

tube heat exchanger together with a

steam regulation valve and

condensate trap can be supplied

Common

• Oxygen Measurement - The result

o the deaeration process can be

measured in-line with an oxygen

measuring instrument, and the values

used to initiate remedial action or

alarms

• Control Panel Enhancements –

Advanced control systems with digital

programming allow extremely accurate

control and comprehensive data

collection Many o these acilities

are also available with PLC control

systems

14



The BlendMaster range covers units

designed or continuous in-line

blending o liquid components

It ensures precise recipe conormity,regardless o whether two or more

liquid components are combined

The BlendMaster is used, or

example, in High Gravity Brewing and

in combination with other unit types

like the CarboMaster or the HGB

Master

Standard capacity range: 50 –1200

hl/h

BlendMaster- adds value

The BlendMaster adds value to

your products and processes in the

ollowing ways:

Product uniormity:

• Ensures exact conformity with the

specied recipe

• High calibration stability


• High precision blending


m2)

Proven security:• Continuous monitoring and

regulation o the combined product

• Automatic switch-off, if offset

exceeds the limit

BlendMaster – In-Line BlendingThe BlendMaster adds new dimensions to accurate standardizing and eciency

Flexible production:• Easy change of recipe for fast

product change

• Turn down ratio 25% of nominal

capacity

• Blending ratio 1:10 to 1:2

Combined blending and carbonation unit




Extract and alcohol are parameters

usually used or duty purposes, and

product declarations and accurate

determination are thereore important

HGB is now a world-wide standard

involving the addition o part o the

brewing water ater ermentation

instead o within the brewhouse

Even when HGB is not a standard

procedure, cutting the nal beer with

small amounts o water to achieve a

consistent product is oten required

Magnetic fow meters are used to

measure the volumes o high gravity

beer and deaerated water Dosing

takes place by means o a simple

ratio control operating a modulating

valve on the water supply This gives

results that are within the accuracy

o laboratory instruments and in-line

measurement This ratio control may

be adjusted by means o an optional

sound velocity/alcohol sensor, whichmeasures the original extract o

the beer and applies appropriate

corrections

This technique can also be used or

blending beer types or diluted beer

rom ltration

Options

• Original Extract Measurement -

Completed through the means o a

sound velocity sensor This measures

the velocity o sound in a ermented

product, which is proportional to the

original extract o the unermented

product• Alcohol Measurement - Density

measurement by means o mass fow

techniques, which together with

sound velocity measurement allow the

alcohol contents to be calculated

• Blending Separation - The simple

DEAERATED WATER

FINAL BEER

HGB BEER

PI

FT

FT

DT

GT

blending “T” can be replaced with a 4

port double seat valve and stop valve

to separate the product and

component loops or cleaning

• High Accuracy Blending – A

variation o this technology using

mass fow measurement is capable o

even higher accuracy and is used or

blending o components such as hop

extract or color

16



The CarboMaster is the answer when

you are looking or a cost eective,

accurate and fexible gas-dosing unit

The CarboMaster range coversunits designed or continuous in-line

injection and dissolving o gasses like

CO2, N2

This equipment ensures a precise

and uniorm injection, by means o

the patented APV gas injector (see

description on page 18)

The CarboMaster is used in the

brewery industry or duties such ascarbonation and can be integrated

with other unit types, including the

BlendMaster or the HGB Master

Standard capacity range: 50 –1200

hl/h

CarboMaster- adds value

The CarboMaster adds value to


ollowing ways:

Product uniormity:

• High dosing accuracy (+/- 0.05g

gas/kg product*)

• Injection independent of inlet

temperature and pressure Economical production:

• No gas losses

• Space-saving design

• Holding time not necessary


• Turn down to 25% of nominal

capacity

• Inject and dissolve up to 10g gas/kg

product

Proven security:

• Constant monitoring andcontrol o nal product


CarboMaster – Carbonation and NitrogenationThe CarboMaster is the answer when you are looking or a cost eective, accurate

and fexible gas-dosing unit

CarboMaster or high Co2 content

* Measured as a standard deviation




The basis o the unit is the patented

APV CO2 special injector, which

diers rom other models by injecting

the liquid into the gas in counter

fow This achieves quick dissolution,

and the gas is tightly bound to the

liquid High levels o CO2 addition

can be obtained without long holding

tubes, and a precise ast regulation is

obtained It is possible to carbonate

sales gravity beer to the desired level

ater the addition o non-carbonated

water

The calculated value is compared

with the measured value and the

CO2 content adjusted appropriately

by means o the modulating valve

The xed head injector can cope with

variation in fow rates o about +10%

The gas supply is shut o i the

product fow stops

Options

• Variable Capacity Head - The xed

head can be replaced with a variable

capacity head which allows a turn-

down to 25% o the nominal capac-

ity This can be either pneumatically

controlled or manually adjusted

• High Carbonation Levels - The

standard system is engineered tocope with levels o CO2 normally

specied in beer Carbonation o up

to 10g/kg CO2 may be obtained i

required

• CO2 Measurement - An in-line CO2

analyzer can be installed together

with a regulating valve to allow the

BEER

CARBONATED BEER

CO2 contents to be automatically

monitored and adjusted

• High Precision Dosing – By means

o a gas fow meter, the amount

o added gas can be accurately

determined to avoid over or under

carbonation This is more accurate

than CO2 measurement with which

it is oten combined A urther ad-

vantage is that the gas usage data

can be used or production control

and statistics by means o a suitable

control system

18



The HGB Master combines the three

process stages o water deaeration

(Derox), inline blending (BlendMaster)

and carbonation (CarboMaster)

into a single, all-inclusive process

The HGB Master ensures a cost-

eective high gravity brewing process

combined with very high production

fexibility The unit is designed

and developed especially or easy

integration with existing lines, and is

available in an extensive and fexible

capacity range

Standard capacity range: 50–1200

hl/h

HGB Master- adds value

The HGB Master adds value to


ollowing ways:

Product uniormity:• Constantly low oxygen content 50

ppb at 12°C* (below 30 ppb at

>20°C*)

• Continuous monitoring for required

specication

• Exact conformity with the specied

recipe

• High calibration stability

• High dosing accuracy (+/- 0.05g

gas/ kg product*)

• Injection independent of inlet

temperature and pressure



• High precision blending


m2)

• No gas losses

• Holding time not necessary


• Variable capacity

• Independent of water inlet

temperature (option)

• Variable deaeration levels

• Easy change of recipe for fast

product change over


capacity

• Blending ratio 1:10 to 1:2

• Inject and dissolve up to 10g gas/kgproduct

Proven security:


tanks

• Constant monitoring and control of

nal product

• Automatic switch-off, if offset

exceeds the limit

HGB Master – High Gravity BrewingThe HGB Master is the result o a compact 3-in-one unit, which deals you all the

aces in the pack

* Measured as a standard deviation





Wide scale use o High Gravity

Brewing has become standard

modern brewing practice, as thereduction in production costs is

signicant By adjusting the extract o

the beer ater ltration rather than in

the brewhouse, the nal output o a

given plant is greatly increased

A High Gravity Brewing Unit

comprises a combination o several

modules described elsewhere The

normal conguration consists o

a deaeration module, a blendingmodule and a carbonation module

The integrated unit is simpler,

more compact and cheaper to

implement than separate modules

The deaerated water is taken rom

the skid to the buer tank and an

amount returned or blending and

carbonation Deaerated water rom

the buer tank is still available or

other applications

Options

• Hot Deaeration – For added security

with poor water quality

• Cold Deaeration – For minimum

production costs

• Blending – Addition of DAW can be

normal or combined with the addition

o pre- and post-run diluted beer• Carbonation – Correction of the

CO2 contents o the nal beer to

specication This is normally a single

point but pre-carbonation o the

water can be supplied i desired

HGB BEER

CO2 /N2

WATER

GLYCOL

GLYCOL

CO2

FINAL BEER

20



The PU Pasteurizer was developed

especially or continuous heat

treatment o beer and other

carbonated drinks

The pasteurization temperature in

the PU Pasteurizers is controlled

by Pasteurization Units (PU) and

designed or high working pressures

The PU Pasteurizer provides eective

and gentle heat treatment o all kind

o carbonated products

Standard capacity range: 50–500

hl/h

PU Pasteurizer- adds value

The PU Pasteurizer adds value to


ollowing ways:

Product uniormity:

• Very high accuracy (computer

controlled PU regulation)

• LowΔ T between product and

heating media


• Large heat regeneration (up to 94%)

with low temperature lling

• Waste-saving design (beer/water

zone)



capacity

Proven security:

• Constant overpressure downstream

• Constant monitoring and control of

nal product

PU Pasteurizer – Controlled Beer PasteurizationI you value gentle and accurate heat treatment you will also value the PU Pasteurizer




Pasteurization is calculated on

the basis o holding time and

temperature The time actor is

linear, and small variations have a

minor eect on the PU value and are

controlled by adjusting the fow Thetemperature actor is exponential

and small variations lead to more

substantial changes in the PU

value The PU value is maintained

by the control system, adjusting

these parameters In the event o

a downstream shutdown, water

replaces the beer in the system to

maintain the balance

The temperature is controlled bymeans o hot water circulation With

a beer pasteurizer, the dissolved

gas must be retained in solution

throughout the process by the

appropriate system pressures The

design system pressure can be set

or each beer type to minimize energy

requirements

The unit is based on a three-

section plate heat exchanger withregenerative, heating and cooling

sections The heating section is part

o a heating cycle in which water is

warmed by means o a shell and tube

heat exchanger The beer temperature

is variable, 72°C held or 30 seconds

being typical

The cooling duty is selected

according to packaging requirements

A regenerative outlet temperature as

close as possible to the packaging

temperature allows reduced energy

consumption

A high-pressure pump supplies

the regenerative section outlet with

the required pressure A booster

pump between the regenerative and

heating sections o the plate heat

exchanger ensures that the pressure

on the sterile side o the regenerative

section is higher than the pressure

on the non-sterile side This pump

is requency controlled to allow

adjustment o the pressure in the

holding cell

A modulating valve is used togetherwith a magnetic fow meter to

regulate the fow and thus the holding

time

The beer enters a buer tank

equipped with a load cell to

measure the contents In the event

o a downstream shutdown, the

pasteurizer continues operation until

a pre-determined maximum level is

reached The remaining beer in thesystem is fushed into the buer

tank with water, which is then re-

circulated to maintain the balance

On resumption o downstream

production, the buer tank is emptied

until a pre-determined minimum level

is reached The water circulating in

the pasteurizer is pushed out to drain

or to a collection tank with resh beer,

and normal operation resumes

The unit is started by means o a shell

and tube heat exchanger heating

water to 80°C or sterilization and

to balance the system Heating o

the system to balance typically takesplace in less than 10 minutes

Options

• Advanced control systems with

digital programming allow even more

accurate temperature and pressure

control They can be combined with

predictive and uzzy logic or extreme

accuracy

• A conductivity meter registers the

interace between beverage and

water and reduces changeover

losses to a very low value

• Valve types and congurations can

be customized as required

• A double shunt for improving the

coolant supply can be integrated

GLYCOL

GLYCOL

BEER

BUFFERTANK

WATER/CIP

WATER

CONDENSATE

STEAM

I R P

22



The production o high quality beer

using highly ecient operating

techniques requires eective, careul

cleaning o equipment APV oers

CIP modules as standardized

compact units or units tailored exactly

to our customers specic projects

and needs

The APV CIP Master is a ully

automatic system, programmed

to achieve optimal cleaning o the

process equipment

The APV CIP Master

– adds value

The APV CIP Master adds value to


ollowing ways:

Product uniormity

• Fully automatic CIP programs ensure

perect cleaning

Economical production• Full automation reduces manpower

• Optimization of functionality leads to

reduced cleaning

Flexible Production

• Easy implementation of options due

to modular design

• The APV CIP Master is skid mounted

when possible, which allows easy

relocation in the event o production

restructuring

Proven security

• If appropriate, the CIP Master is fully

tested beore delivery

• Proven functionality and reduced

commissioning time

Functional

description

The APV CIP Master is a ully

automatic, sel-contained unit

It comprises a complete set o

equipment or CIP, including, or

example, tanks or water, acid and

caustic soda, pumps, tubular and/

or plate heat exchangers, valves and

instrumentation such as conductivity

and fow transmittersThe CIP program covers the

complete cycle Detergent or water

selection, detergent concentrations

and cycle temperatures and times are

ully controlled

The APV CIP Master is ully

integrated with the process line and

can be used with existing equipment

(including lling machines) as well as

new APV units

The design o the CIP Master by

APV incorporates the requirements

o production schedules to minimize

downtime This orms the basis

or selecting the appropriate tank

numbers and volumes together with

the number o lines

The standard APV control consists

o a controller with an operator panel

The signal exchange between the

instruments/controller/control room is

perormed using a bus system

Options

• 3, 4 or 5 tank systems

• Different tank sizes

• Number of lines

• Tubular or plate heat exchangers

• Low cost manual CIP systems

• Customer specic equipment

• PC solutions based on Wonderware

FactorySuite™

• Modem connection for remote

controller service

CIP MasterGo or perect cleaning results at lower cost with the APV CIP Master



Fermentation & Maturation

Proper ermentation requires wort

cooled to the right temperature,

aerated to the right oxygen content

and dosed with the right amount

o active yeast cells APV designs

highly automated process systems

that continuously control all essential

parameters beore and duringermentation and maturation, ensuring

an end product o a consistently high

quality

The control systems o ermenter

cooling and the process system are

designed to provide cohesive support

to brew masters, process engineers

and automation specialists to help

them to meet the requirements or

specic beer types The result is

a complete and well-documented

process line designed to maintain

the characteristics o the beer and to

meet consumer expectations or high

quality

FiltrationDue to seasonal fuctuations in the

quality o the raw material and the

complexity o the process itsel,

ltration is one o the more complex

parts o the brewing process APV

works in close co-operation with

reputable suppliers o ltration

systems to meet the needs o aspecic project

It is important to control the dierent

phases o the ltration process and

integrate them into the rest o the

beer processing line, ensuring that

the required production capacity is

reached

APV, An SPX Brand105 CrossPoint ParkwayGetzville, NY 14068Phone: (716) 692-3000 (800)207-2708 Fax: (716)692-1715E-mail: answersus@apvcom

For more inormation about our worldwide locations, approvals, certications, and local representatives, please visit wwwapvcom

SPX reserves the right to incorporate our latest design and material changes without notice or obligationDesign eatures, materials o construction and dimensional data, as described in this bulletin, are provided or your inormation only andshould not be relied upon unless conrmed in writing Certied drawings are available upon request

Your local contact:

Documents

Beer Processing Solutions 5600 01-08-2008 US